Contact tip rotary lock of a welding torch

Abstract

A welding torch system includes a diffuser assembly that includes a locking mechanism to receive a contact tip. Additionally, the welding torch system includes the contact tip, which includes locking elements configured to interact with the locking mechanism of the diffuser assembly to secure the contact tip within the diffuser assembly. Further, the contact tip is rotated within the diffuser assembly to securely align the locking elements with the locking mechanism.

The invention claimed is: 
     
       1. A contact tip of a welding torch, comprising:
 an elongated body comprising:
 an electrically conductive material, 
 an inner surface, and 
 an outer surface encircling the inner surface, the elongated body being centered about a tip axis, and the outer surface comprising:
 a front portion, at least part of the front portion encircling a front opening, 
 a rear portion, the rear portion being frustoconical, and at least part of the rear portion encircling a rear opening, and 
 a middle portion positioned between the front and rear portions, the middle portion being cylindrical; 
 
 
 a bore extending through the elongated body from the front opening to the rear opening; and 
 a locking element comprising a wall extending radially outward from an intersection of the middle portion and the rear portion of the outer surface of the elongated body in an axis perpendicular plane that is perpendicular to the tip axis, wherein an outer diameter of the contact tip is larger at the locking element than at the middle portion of the elongated body, and the outer diameter of the contact tip varies around the outer surface of the elongated body in the axis perpendicular plane. 
 
     
     
       2. The contact tip of  claim 1 , wherein the axis perpendicular plane comprises a first axis perpendicular plane, the wall comprises a first wall, and the locking element further comprises a second wall extending radially outward from the outer surface of the elongated body in a second axis perpendicular plane that is perpendicular to the tip axis, the locking element further comprising a connecting wall that connects together the first wall and the second wall. 
     
     
       3. The contact tip of  claim 1 , further comprising a plurality of locking elements, the plurality of locking elements comprising the locking element. 
     
     
       4. The contact tip of  claim 3 , wherein the plurality of locking elements are discontinuous from one another. 
     
     
       5. The contact tip of  claim 4 , wherein the plurality of locking elements are equally spaced around the elongated body. 
     
     
       6. The contact tip of  claim 5 , wherein at least a portion of each locking element of the plurality of locking elements lay in the axis perpendicular plane. 
     
     
       7. The contact tip of  claim 2 , wherein the second wall is spaced away from the first wall by a first distance in a first direction that is parallel to the tip axis. 
     
     
       8. The contact tip of  claim 1 , wherein the locking element comprises a first locking element, the contact tip further comprising a second locking element extending radially outward from the outer surface of the elongated body. 
     
     
       9. The contact tip of  claim 5 , wherein the plurality of locking elements are arranged in a ring formation around the elongated body. 
     
     
       10. The contact tip of  claim 1 , wherein the elongated body is hollow and the locking element is integral with the elongated body. 
     
     
       11. A contact tip of a welding torch, comprising:
 an elongated hollow body comprising an electrically conductive material, the elongated body being centered about a tip axis; and 
 a plurality of locking elements integral with, and extending radially outward from, an outer surface of the elongated hollow body, the plurality of locking elements being discontinuous from one another and equally spaced around the elongated hollow body in an axis perpendicular plane that is perpendicular to the tip axis. 
 
     
     
       12. The contact tip of  claim 11 , wherein the elongated hollow body comprises a front portion, a rear portion, and a middle portion positioned between the front and rear portions, the outer diameter of the contact tip being larger along an entirety of the middle portion of the elongated hollow body than at any point along the front portion and rear portion of the elongated hollow body. 
     
     
       13. The contact tip of  claim 12 , wherein the rear portion is frustoconical and comprises the axial end, and the middle portion is cylindrical. 
     
     
       14. The contact tip of  claim 12 , wherein the rear portion comprises a rear opening and the front portion comprises a front opening, the contact tip further comprising a bore extending through the elongated hollow body from the front opening to the rear opening. 
     
     
       15. The contact tip of  claim 12 , wherein the locking elements extend radially outward from the middle portion, such that an outer diameter of the contact tip is larger at the locking elements than at the middle portion of the elongated hollow body. 
     
     
       16. The contact tip of  claim 11 , wherein the elongated hollow body is configured to mount without tools to a diffuser assembly mounted to a welding torch, and the locking elements are configured to interact with locking shoulders of the diffuser assembly upon rotation of the contact tip while the locking elements are within the diffuser assembly. 
     
     
       17. The contact tip of  claim 15 , wherein the plurality of locking elements are arranged in a ring formation around the elongated hollow body. 
     
     
       18. The contact tip of  claim 15 , wherein the elongated hollow body has a diameter between 0.325 inches and 0.4 inches, inclusive. 
     
     
       19. The contact tip of  claim 15 , wherein the locking elements are positioned at an intersection of a cylindrical section of the middle portion and a frustoconical section of the rear portion. 
     
     
       20. The contact tip of  claim 15 , wherein the plurality of locking elements comprises a first locking element comprising a crescent wall extending radially outward from the outer surface of the elongated body in the axis perpendicular plane.